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Industrial Attachment

Of

Alltex Industries Limited

Submitted by

WWW.ASSIGNMENTPOINT.COM

www.AssignmentPoint.com

Alltex Industries Limited is a one of the largest Textile industry in Bangladesh. It has the state of the machinery & follows modern mechanism for production. Alltex Industries Limited Produces yarns for woven so it is the leading composite Textile industry.

With the establishment of Alltex Industries Ltd. we have been able to save and directly contribute about 50 million in local currency to the national exchequer. Moreover we have been also able to bring reduction in the price structure with supply of quality product and creation of employment opportunity. Since the company’s only aim is to serve the customers for their maximum satisfaction then it has given foremost importance to:

Sustainable price

Guarantee of quality product

Thus its mission is to provide Bangladesh with high quality Home-tex fabric. A team of excellent efficient work force is in its employment who feels a homely atmosphere in the company. We try to give them liberty to contribute their best in production of quality products and imparting high quality services to the utmost satisfaction to its customers. They work here with perfect zeal and responsibilities in co-operative unison. Catering to the home market our vision is to cross the border and let our product to enter into world market.


Chapter-One

Introduction

Introduction If the theoretical knowledge is a glass of water then the practical knowledge would be drinking of the water. It is always very easy to make a man understand about a firebox by showing and lighting practically rather than describing theoretically who has not ever seen a firebox. So, for any technical education the practical experience is the most important as well as the theoretical knowledge.


As we are studying in a technical line, it is always important for us to gather the practical know-ledge. Through our study life the only biggest chance for us to combine the theoretical know-ledge with the practical knowledge is the „Industrial Attachment period‟ that comes only once in the education life. So we can easily realize the importance of Industrial Attachment. And in addition the knowledge we gathered from the industrial training reflects in the report of industrial attachment note book.

So industrial attachment is the process where the trainee can blend his theoretical knowledge with practical knowledge increasing his/ her ability of work, skillness, performance and attitude and so on. It also provides sufficient knowledge about production management, productivity evaluation, work study & efficiency, industrial management, production planning and control, production cost analysis, inventory management, utility, maintenance and so on. Industrial attachment makes us reliable to be accustomed with the industrial atmosphere and also improve courage and inspiration to take self-responsibility.

I tried my best to prepare this note book applying our best efforts. We tried to gather all the necessary information to make it a valuable for me as well as for everyone. I think it will help us a lot in future in my practical life.


Chapter-Two

Company Profile

NAME : ALLTEX INDUSTRIES LIMITED

TYPE : A Public Limited Company


FACTORY : ARIABO, RUPGANJ, NARAYANGANJ,

(22 Km from Dhaka City)

OFFICE : 139, MOTIJHEEL COMMERCIAL AREA,DHAKA-1000, BANGLADESH.

Tel : (880-2) 9569192, 9566085Fax : (880-2) 9565569, 9567293E-mail : [email protected] .

YEAR OF ESTABLISHMENT : 1986.

PARENT ORGANIZATION : BASTU SHILPI GROUP(Established in 1972)

PRODUCT:

(A) (1987 – 1991) : DYEING FINISHING FOR LOCAL MARKET.

(B) (1992 – to date) : PRINTING AND DYED BED SET, DUVET SET CURTAINS AND OTHER HOUSE HOLD TEXTILES (100% EXPORT ORIENTED).

PRESENT CAPACITY:

(A) PROCESSING : PRINTING – 2,000,000- Mtrs./Month (2 Rotary) DYEING - 1,500,000- Mtrs./Month (Jet Dyeing, Pad Dyeing,

Jigs & Thermosol Dyeing). (B) STITCHING & PACKING : 8, 50,000 Units/Month.

PRESENT WORKING AREA : (A) PROCESSING SECTION - 80,000 Sq. Ft.(B) STITCHING SECTION - 62,000 Sq. Ft.

Different Department of Alltex Industries Limited:


mailto:[email protected]

A) Production Oriented Department:

Spinning Woven fabric pretreatment Dyeing Printing Stitching Quality assurance Maintenance Utility Finishing Quality control Export

B) Supporting department: Personnel administration Procurement Marketing HRD Finance & Accounting Inventory management

Remarks: Available data on physical infrastructure was not available. The management should be certified by ISO 9001:2008.


Chapter-Three

Manpower Management

Internal Communication:


Employees at Alltex Industries Ltd. have organizational freedom to work but with a certain chain of command for quality management system and their effectiveness. The organizational chart (Organ gram) is used to communicate concerns to the appropriate parties. Following media is used for effective Communication: Telephone and PABX services Office Memo Meetings Cell phone

Shift Change:

There are three shifts in this industry. So the shifts are changed at every 8 hours.

Responsibilities of a production Officer:

1. To give dyeing program slip & weave slip. 2. To match production sample with target shade & weave structure. 3. To collect production sample lot sample matching next production. 4. To observe dyed fabric during finishing running & also after finishing. 5. To identity disputed fabrics & report to P.M/G.M. for necessary actions. 6. To discuss with P.M about overall production if necessary. 7. To sign the store requisition & delivery challan in the absence of P.M. 8. Also to execute overall floor works. 9. To maintain loading/unloading khata. 10. Any other assignment given by higher authority.

Job Summary: To plan, execute & follows up the production activities & control the quality production with related activities.

Job Description of Production Executive: Overall supervision of dyeing, finishing production. Batch preparation & pH chock. Dyes & chemical requisition issue & check. Write Fabrics loading & unloading time from m/c Program making, sample checking, color measurement Control the supervisors, operator, asst. operator and helper of Dyeing m/c. And also any other over work as & when required by the management

Job Summary:To plan, execute & follows up the production activities & control the quality production with related activities.


ORGANOGRAM OF ALLTEX INDUSTRIES LIMITED:


Chairman

Managing Director

C. O. O.

Director Admin HR, Compliance

Director Sales & Marketing Director

Technical

Director

Operation

G. M. Weaving

D. G. M. Admin HR, Compliance

Manger

Assistant Managers

Senior Officer

Junior Officers

Staffs

Peons

PeonPeonPeonPeonPeonPeonPeon

Cleaner

Manger

Senior Officers

Assistant Manager

Senior Officer

Junior Officer

Staffs

G. M. Stitching G. M. Admin HR, Compliance

P. M. Weaving

Senior P. O.

Weaving P. O. Weaving

Senior Weaver

Weaver

Helper

P. M. Stitching

Senior P. O.

Stitching P. O. Stitching

Senior Operator Operator

Helper

Manager Quality

Mechanical & Electrical Officer

Operator

Helper

Staff

Cleaner

Quality Assurance Manager

Working shift:

The man power management system of Alltex Industries Ltd. is well arranged. Every officers & stuffs are responsible for their duty.

The workers are bounded to work for minimum 8 hours.

1st shift: 6:00 A.M – 2:00 P.M

2nd shift: 2:00 P.M – 10:00 P.M

3rd shift: 10.00 P.M – 06:00 A.M

General shift: 9:00 A.M – 06:00 P.M


Chapter-Four

Products & buyers


List of Product:

1. PRINTED AND DYED (Pigment & Reactive Prints & Dyed):-

BED SHEET.

DUVET COVER

FRILLED VALANCE SHEET.

QUILT COVER.

PILLOW CASE.

BULLSTAR.

FITTED SHEET.

FITTED BOX VALANCE SHEET.

ENVELOP SHEET.

CURTAIN.

PLEMEAT.

COMFORTER SHELL.

DUST RUFFLE.

WINDOW VALANCE.

SHAM.

AND

OTHER HOME TEXTILE ITEMS.

2. NON – IRON FINISHED:

o PINTUCK,

o HEMSTITCH,


o EMBROIDERY

&

o LACE PRODUCTS.

List of Buyers:

MARKS AND SPENCER

LAURA ASHLEY

AU NATURALE

IKEA

HEMTEX

LECLERC

LEON KRMEKER

WILKINGSONS

ROSEBUYS

LITTLEWOODS

TESCO


ARGOS

HOMEBASE

K-MART

WOOLWORTH

HOUSE OF FRASER

DEBENHAMS

NEXT

AIS

GRATTAN

Z-X-Y

EKKELBOOM

FOTEX

CARRE FOUR

SAINS BURRY

MECRO

MORRISONS

DUNNES

TESCO (GREEN SEAL)


Chapter-Five

Raw Materials


Raw material is a unique substance in any production oriented textile industry. It plays a vital role in continuous production & for high quality fabric. For producing HOMETEX fabric ring (carded and combed) yarn, reactive dye, pigment color, sizing materials etc are used. For the production of home-tex fabric there are several types of raw materials as-

Yarn (warp & weft) Dyestuff Size materials Chemicals & auxiliaries Accessories.

Common Yarn Sizes for Hometex: 20 ne. 24 ne. 30 ne. 40 ne. 22 ne.

Yarn suppliers:

Jamuna Spinning Mills Limited. Muzaffar Spinning Mills Limited. Jaba Spinning Limited. Fariha Spinning Mill Limited etc.

Sizing Chemicals:

Starch: Penetrose-50 Amisal- 055400

Tapioca starch Apple starch Sizetex-05

Binder: elastex-3040

Elastey-3040

PVA

Ecosize-A

Penflex-cs9010


Softener: Elastex CSTTallowPenflex k- 300

Dyestuffs: Novacron Dyes- Reactive. Levafix Dyes- Reactive. Megapix Dyes- Reactive. Ramazol dyes- Reactive. Drimarine Dyes- Reactive Dianix Dyes- Reactive Forosol Dyes- Disperse. Planil Dyes-Disperse. Foron Dyes- Disperse. Pigments color.

Chemicals & auxiliaries:

Different types of chemicals & auxiliaries are needed for denim sizing & dyeing. In Alltex, we are using the followings.

Hydrose Sodium sulphide Caustic Albaflow PAD Premazol Triplex Setamol Tex-o-film Penetrose Textile wax Kollotex-5 Avetex-K Subitol Acetic Acid Setamol WS Sodium Sulphide stone


Glissofil Extra Soft

Chapter-Six

Sequence of Operation


Sequence of Operation in ALLTEX INDUSTRIES LIMITED:


Yarn received from Spinning or Supplier

Warping, Sizing and knotting, Drawing, Denting

Weaving as per Requirement

Mending and Folding

Back Process (singeing, Scouring, Bleaching, Mercerizing as per requirement)

Dyeing Printing

Stitching Section (spreading, cutting, stitching, quality, pressing, folding, packing)

All the quality parameters maintained

Disposal of finished goods

Spinning

Weaving

Processing

Stitching

Export


Flow Chart of Hometex Manufacturing

Process Flow Chart of Alltex Spinning Ltd.


Process Flow Chart of Alltex Fabrics Ltd


Yarn received from store

Warping

Sizing

Beaming

Knotting, Drawing, Denting

Weaving as per Quality

Mending and Folding

Disposal to processing Unit

Sizing

Cure

Print

Batch

Bleach

Scour

Rotation

Singeing + Desizing

Printing

Delivery to Stitching

Testing

Fold/ Inspection

Calendaring

Finish

Dyeing

Batch

Mercerize

Batch

Bleach

Scour

Rotation

Singeing + Desizing

Continuous Dyeing Process

Dry

Jigger Dyeing

Heat Sat

H.T. Dyeing

Neutralize

Mercerize

Batch

Bleach

Scour

Rotation

Singeing + Desizing

Conventional Dyeing Process

Dyeing

Grey Inspection/ Issue

Processing

Process Flow Chart of Processing Unit


Process Flow Chart of Stitching Section

Fabric receiving and issuing

Spreading

Cutting Stitching In line Quality check Folding Quality Table check (100% goods) Pressing and Folding Folding In line Checking Packing Cartooning


Final checking Audit as per AQL level 2.5 or as per buyer requirement

Chapter-Seven

Production Operation & Machineries

Spinning Unit ALLTEX SPINNING LIMITED


Alltex Spining Limited was established in 2005 with a view to produce quality yarn for export purpose. ASL is producing Yarns for Alltex Fabrics Ltd. to meet the export requirement. To work in a systematic manner here working many experienced Pakistani people from production programming to technical support in collaboration with Bangladeshi people.

Collection of raw materials of ASL:

Cotton is the main and only materials of ASL. And ASL collects this raw material from Pakistan. The materials are:

a. 100% raw Cotton,b. Polyester Cotton.

Division of Spinning:

ASL spinning totally divided by three (3) sections. The sections are:

a. Back,b. Ring,c. Finishing & Wending.

Description of the three (3) section of ASL:

a. Back section: Back section totally divided by four (4) parts. The parts are:

1. Blow room,

2. Carding,

3. Drawing,

4. Simplex.

Description of the four (4) parts of Back Section:

1. Blow room: The raw cotton is refining here and wastage separate from raw cotton in this section. The processing of Blow room and its machines is following:


Uni Flocks (2 machines).

▼

Mono Cylinder (1 machine) > First stage of wastage separate.

▼

Fine Opener (1 machine).

▼

Securomate (1 machine).

▼

Unimix (1 machine).

▼

Aromix (1 machine).

▼

ERM (2 machine).

▼

Multi mixer chamber (3 machines 1 is running) >Average clean the cotton.

2. Carding: Short cotton separating here sliver make in this section.

Machines: Total machine - 20 (twenty). All machines are made by Switzerland.


Types of machine: ♦ C ½ → 10 Pieces.

♦ C 4 → 08 Pieces.

♦ C 50 → 02 Pieces.

Brand Name: Reiter.

Note: ♦ If machine speed is more slow than fiber quality will make fine.

♦ Speed up & down by machine belt.

♦ Slivers quantity - 22 kg per can.

3. Drawing: In this section - from 6 (six) can sliver to make 1 (one) can sliver. Processing are following:

1st Rider ─ 6 (six) can sliver make 1 (one) can sliver.→ 3500 Miter Sliver.

2nd Rider – 6 (six) can sliver make 1 (one) can sliver.→ 4000 Miter Sliver.

Machine Name & Quantity: Finisher drawing machine.

Total machine quantity 9 (nine) pieces but running 6 (six) pieces.

Machine type: Two types of machine here and those are –

■ RSB – 51 – (6 Machine).

■ RSB – 851 – (3 Machine).

Production: 450.00 miter per minute.

26 Can in 8 (eight) hour.

4. Simplex: It is last section of back section. In this section Sliver make Robbing.

Name of the Machine and Quantity: Reiter Margolis total 6 (six) machine running 5 (five) machine.


Type: F 4/1 – 96 models.

F 1/1 – 87/88 models.

Production: 1100 to 1200 meter per 1 to 1 ½ hour.

Note: Robbing counts in Hanks.

# Hank = Length X Wait (Unit)

Wait X Length (Unit)

# From 00.90 hanks to make 24 count yarns.

2. Ring Section: Yarn making from Robbing in this section.

Machines Name and Quality: Name of the machine: ♦ Ring Frame,

♦ Long Frame,

♦ Short Frame,

♦ Spindle – Ring Cops.

Quantity of the machines: # all frames machine 20 pieces running 14 pieces.

# Spindle 21000 pieces.

Note: Spindle means where the Ring Crops installed.

Production: ♦ Per Spindle produce 143.00 gm Yarn in 8 hour.

♦ Long Frame 430.00 kg in 24 hour.

♦ Short Frame 225.00 kg in 24 hour.

♦ 2700.00 kg yarns produce in 24 hour or per day.


Note: # Per Ring Cops yarn produces 41.16 gm.

# 146.00 gm Robbing needs to produce 143.00 gm yarn.

# Count changed by Draft.

# 900.00 gm yarn produced by 1000.00 gm robbing.

3. Finishing & Winding: In this section yarn Rolls/Wending on yarn cone by ring cops.

Machines Name and Quantity: Auto Conner total 15 pieces but 11 pieces machine is running at this moment for parts and technical problem.

Note: ♦Per cones weight is 2.83 kg.

♦ 24 cones per yarn packet/bag.

♦ 51.245 kg yarn per packet/bag.

♦ 1.245 kg weight for the pepper cone and the bag in packing.

♦ 50.00 kg yarn per packet/bag.

♦ 2.50 tones yarn produce per day from ASL.

Laboratory / Quality Control Room

It’s a very important part for ASL because Yarns Quality, Count, Strength is cheeked and control from here. There are various machines for the lab test / quality control. The machines are following:


1. Wrap Block: It is use for measurement the Sliver in meter.

2. Stand Scale: By this scale cont weight of Sliver in Pound/Lbs.

3. Lea Strength Tester: By this machine yarn count in Yards (Yds) for take Strength and Count.

4. Yarn Board: By this machine make bundle of Yarn for taking weight per 1000 meter.

5. Digital wait balance: It’s a digital electrical weight balance machine it is used for count Weight of Sliver and Yarn.

6. Uster Tester: It’s a very important machine for every spinning mill. By this machine Count Slivers and Yarns IPI, UM, MEPS, Thickness, Strength etc.

Weaving Unit ALLTEX FABRICS LIMITED

Warping UnitSteps to be followed:


Receiving yarn cone from store Checking yarn quality as per buyer requirement in the testing laboratory

I) Yarn countii) Yarn weightiii) Yarn composition

Arrangement of yarn crelling in warping machine according to fabric construction Determination of wrapper’s in warping machine

Types of Yarn

Comb yarn Curd yarn Rotor yarn

General defects of Yarn :

1. Count variation2. Shade variation3. Slab4. Naps5. Hairiness6. TPI (Twist per inch) variation7. CSP (Count strength per lee) variation8. IPI ( Intersection per inch) variation9. Cone weight variation10. Thickness & thinness variation of yarn

Yarn Composition

1. 100% Cotton2. Poly Cotton (PC)3. 100% Polyester

Running Yarn Quality

20 Count 22 Count 24 Count 30 Count 40 Count

Warping:


Warping is the process of transferring multiple yarns from individual yarn packages onto a single package assembly. Normally, yarns are collected in a sheet form where the yarns lie parallel to each other and in the same plane onto a beam, which is a cylindrical barrel with side flanges. Warping means winding the warp yarns parallel from package to beam with required number, length and tension. Good warping is as important as sizing. Because good quality of warping always ensure good quality sizing and weaving, as well as good quality of fabric. Both efficiency and profit can be increased by a good warping.

Objects of warping-

1. To prepare the pre-beam. 2. To wind the yarn from the package (got from the spinning mill – cone, cheese, bobbin etc). 3. To wind the yarn parallel to each other. 4. To maintain the uniform length of each & every yarn.

Machine Specifications of warping machine in AFL:

Warping Machine: 01Machine manufacturer : West Point Mode l: 74495Origin: Georgia, USA Creel type: Magazine creel Creel capacity: Maximum 600 packages Tensioning method: Disk & plate Rpm: Maximum 800 & Minimum 300

Warping Machine: 02Machine manufacturer: Schlafhorst Model: MZ D10/76Origin: Western GermanyCreel type: Magazine creel Creel capacity: Maximum 700 packages Tensioning method: Disk & plate Rpm: Maximum 800 & Minimum 300 Sizing Unit

Steps to be followed:

Receiving warp beam from warping unit Loading warp beam according to the program on the sizing stand in order to size the yarn

in sizing machine. Preparing of sizing chemicals in cooking kettle according to given recipe.


Sizing the yarn in sizing machine to make sizing beam as per requirement Sending the sizing beam to loom unit

Basic Chemicals used for Sizing

1. Starch2. Tallow3. Wax4. Size CA5. Texo plast6. PVA

General Defects of Sizing:

1. Less size2. Hard size3. Sizing spot4. Turn yarn5. Crossing yarn6. Beam width7. Over or under dry

Machine Specifications of sizing machine in AFL:Machine manufacturer : West Point Model : B85648 Origin : Georgia, USACapacity : 7000 endsNo. of warp beam : 18 (maximum)No. of Dryer Cylinder : 12Pressure/ Immersion Roller : 02Guide Roller : 06No. of Size-box : 02

Loom UnitSteps to be followed:

Receiving sizing beam from sizing unit. Drawing / knotting of weaver’s beam Setting the weaver’s beam on the loom Loom setting


Weaving the fabric according to quality Doffing of fabric roll from the loom Sending the fabric roll to mending & folding unit.

Weaving:

The process of interlacing warp yarn with the inserted weft yarn in a definite order to form a fabric suitable for use as a dress material or industrial purpose is called weaving. The matching used for this purpose is called loom.

The weaving process interlaces the warp, which are the length-wise indigo dyed yarn and the filling, which are the natural-colored cross-wise yarn. The warp thread is in the form of sheet. The weft thread is inserted between two layers of warp sheets by means of a suitable carrier, such as Shuttle, Projectile, Rapier, Air current, Water current, etc. The selection of carrier depends upon the type of weaving machinery used. The two different technologies available for weaving machines are - Conventional Shuttle Weaving System which is done by Ordinary Looms or Automatic Looms; and the Shuttle less Weaving System which is done by Air jet, Water jet, Rapier, or a Projectile weaving machine. The Conventional Shuttle loom results in lesser production due to slow speed and excessive wear and tear of machinery. In practice, the weaving machines are named after their filling insertion systems. Based on the filling insertion systems, the weaving machines can be classified as shuttle and shuttle less weaving machines. Shuttle loom have been used for centuries to make woven fabrics. In this type of loom, a shuttle, which carries the filling yarn wound on a quill, is transported from one side to the other and back


In figure- (1) Warp beam (2) Back rest roller (3) Drop wires (4) Motor driving the warp let-off (5) Heald frame (6) Motor driving the fabric takedown (7) Slay(8) Reed(9) Weft(10) Take down roller(11) Cloth beam

Auxiliary Functions:

In addition to the five basic motions of a loom there are many other mechanisms on weaving machines to accomplish other functions. These include:

A drop wire assembly, one wire for warp yarn, to stop the machine when a warp end is slack or broken

A tension sensing and compensating whip roll assembly to maintain tension in warp sheet A mechanism to stop the machine when a filling yarn breaks Automatic pick finding device reduces machine downtimes in case of filling yarn brea-kages

Filling feeders to control tension on each pick Pick mixers to blend alternate picks from two or more packages Filling selection mechanism for feeding multi-type filling patterns


Filling selvage devices such as trimmers, tuckers, holders and special weave harnesses for

selvage warp ends Filling replenishment system to provide un-interrupted filling insertion by switching from a

depleted to a full package A temple assembly on each selvage to keep fabric width at the beat-up as near the width of

the warp in the reed as possible Sensors to stop the machine in the event of mechanical failure A centralized lubrication control and dispensing system A reversing mechanism to avoid bad start ups after a machine stop A color coded light signal device to indicate the type of machine stop from a distance A production recording system

Loom specification of AFL:

SULZER (MODEL –TW11 & PU) (153” WIDTH) 100 NOS.PROJECTILE LOOM (130” WIDTH) 103 NOS

Main parts of loom:Main motor, Hydraulic brake motor, Cutter motor, ELCA motor, Waste cutter motor, Heald shafts, Reed, Gripper, projectile, Chain, Cam and cam shedding, Clutch, Sensor, Cutter, Pre-winder, Load cell, Back rest, Sensor, Take up roller, Let off roller etc


Loom motion: Each and every machine has some certain movements or motions. A weaving is distinguished from other machines by its specific movements or motions. These motions are divided into two categories as follows: Primary motion. Secondary motion.

Primary mechanism: Primary, essential or fundamental are designed to those motions or movements of weaving in absence of any of them weaving are not practicable. These are fundamental or essential mechanisms. Without these mechanisms, it is practically impossible to produce a fabric. It is for this reason that these mechanisms are called ‘primary’ mechanisms. The primary mechanisms are three in number. 1. Shedding 2. Picking 3. Beating

Shedding: Shedding is the first and primary mechanism of Weaving. During weaving, the total warp yarns are divided into two groups called shedding. Two groups of warp yarns are made in the loom by raising and lowering of heald frames by the use of a Tappet. The tappets may be plain or twill that is according to fabric structure to be made. Besides tappet shedding, there are some other shedding mechanisms also available. Dobby shedding and jacquard shedding is also well known to the weavers.

Picking: Picking is the second primary motion of weaving mechanism. As the shed is formed in the loom, the weft yarns are passed through the shed by picking mechanism. Generally a shuttle with a weft yarn in the shed. There are various types of picking mechanism available in the loom, to pass the weft yarn through the shed. Rapier, projectile, water jet, air-jet etc. weft insertion mechanism is popular all over the world.

Beating: Beating is the third primary motion. When the weft yarns are laid in the shed, this weft yarn is smoothly placed to the fell off the cloth in a regular way by the movement of the reed, which is secured in the sley. The sley moves to & fro by gearing connection. The above mentioned three


primary motions of a loom i.e. shedding, picking, beating is per-formed in a cyclic order and the fabric is produced. Then the fabric is passed over the front rail and wound of the cloth roller.

Secondary Mechanisms: These mechanisms are next in importance to the primary mechanisms. If weaving is to be continuous, these mechanisms are essential. So they are called the „secondary mechanisms. They are: a. Take-up motion b. Let-off motion.

Take-up motion:

The take-up motion withdraws the cloth from the weaving area at a constant rate so as to give the required pick-spacing (in picks/inch or picks/cm) and then winds it on to a cloth roller.

Let-off motion:

The let-off motion delivers the warp to the weaving area at the required rate and at constant tension by unwinding it from the weaver’s beam. The secondary motions are carried out simultaneously.

Auxiliary Mechanisms: To get high productivity and good quality of fabric, additional mechanisms, called auxiliary mechanisms, are added to a plain power loom. The auxiliary mechanisms are useful but not absolutely essential. This is why they are called the „auxiliary‟ mechanisms. These are listed below-a. Warp protector mechanism. b. Weft stops motion. c. Temples.d. Brake e. Warp stop motion (Predominantly found in automatic looms)

Warp protector mechanism:


The warp protector mechanism will stop the loom if the shuttle gets trapped between the top and bottom layers of the shed. It thus prevents excessive damage to the warp threads, reed wires and shuttle. Weft stops motion: The object of the weft stop motion is to stop the loom when a weft thread breaks or gets ex-hausted. This motion helps to avoid cracks in a fabric.

Temples: The function of the temples is to grip the cloth and hold it at the same width as the warp in the reed, before it is taken up. Brake:The brake stops the loom immediately whenever required. The weaver uses it to stop the loom to repair broken ends and picks.

Warp stop motion: The object of the warp stop motion is to stop the loom immediately when a warp thread breaks during the weaving process.

Loom motions of AFL:

1. SHEDDING: Cam shedding produced by STAUBLI Total no of heald frame: Number of held shaft is eight but generally used three to six held shafts. Cams are driven from individual motor used only for the shedding RPM of the motor: 950

2. PICKING: Picking is done by projectile. Picking starts at 65 degree and arrive to next end at 240 degree. 3. BEAT-UP: Torsion bar beat-up mechanism is used. Reed is used for beat-up.

4. LET-OFF: Positive let-off Individual motor is used There are load cell on back rest which sense the tension on the warp sheet The sense is transferred to the let-off motor which release required length of warp.Stop motion indication:

Red: red light is on due to warp yarn breakage. Yellow: yellow light is on due to weft yarn breakage. Green: green light is on due to machine stop intentionally. White: white light is on due to mechanical problem.


Red & green together: red & green light is on due to finish of warp stop Yellow & green together: yellow & green light is on due to finish of weft

package.

Weaving faults:

Here we tried to introduce some fabric faults occurred in Alltex Fabrics Ltd. during our internship period.

Starting mark: Causes: - Main cause is loom stoppage.

Remedy: - This cannot be avoided but can be controlled by starting mark setting or starting the loom by reversing the loom.

Reed mark: Causes: If any fault occur at reed.

Faulty denting in the reed.

Remedy: Right selection of the reed and right denting.

Filling stop: Causes: If weft is failed to reach FD1

If weft is too long and reach FD2

Remedy: Correct setting of the weft length.

Correct setting of projectile guide.

Proper setting of picking pressure.

Proper setting of pre-winder.

Proper setting of creel position

Snarl: Causes: Excess main nozzle pressure

Low filling tension


Remedy: Control of projectile speed.

Correct setting of the PFT finger value

Double pick: Causes: Cutting problem of the cutter

Faulty setting of the air pressure

Remedy: Cutter position is to be set correctly

Air pressure should be reset

Miss pick/ broken pick: Causes: Excess air pressure of main nozzle

Remedy: Main nozzle air pressure should be reduced

Warp breakage: Causes: Bad sizing Low strength of the yarn Crossing of the warp yarn Loose or tight yarn Remedy: Re knotting Proper sizing

As a new beam (or article) is set to a loom either by drawing cum gating or tying, it is the task of the loom technician to check and set all necessary settings, gauging operating values through the loom function panel and mechanical means. After all setting has been done slow running or in-ching checks the loom function. The first meter of the fabric is made with normal running and cut off from the loom and checked over an inspiration box against light. Fabrics checked visually for the followings- 1. Any wrong pattern setting 2. Any wrong drawing & denting 3. Fabric width, warp & weft density 4. Any other cloth defect.


Product quality check:

The fast meter of the fabric is made with normal running and cut off from the loom and checked over an inspection box against light. The fabric is checked visually for – 1. Any wrong pattern setting 2. Any wrong drawing & denting 3. Fabric width, warp & weft density 4. Any other cloth defect Any fault found in the fabric is corrected over the loom and is hand over to the operator for nor-mal running.

Types of Weave

1. 1/1 Plain Weave2. 2/1 or 1/2 Twill3. 3/1 or 1/3 Twill4. 4/1 or 1/4 Satin

Mending & Folding Unit

Dfinition of Mending: Mending is a process of minimize of fabric fault.


Receiving the fabric roll from loom unit Unfolding the fabric from fabric roll Properly checking the fabric on mending table according to 4 point system Mending the fabric if there is any fault Folding the checked fabric in folding machine Recording the fabric in the register Sending the fabric to warehous

General Defects of Weaving

1. Selvedge fault2. Yarn slub3. Hard sizing4. Miss pick5. Float mesh6. Mesh7. Temple mark8. Oil spot9. IRO fault10. Hole


11. Guide mark12. Fungus13. Broken ends14. Starting mark15. Cut pick16. Yarn fault17. Thick & thin18. Lashing mark

4 Point System

4 point system is approved by American Apparel Manufacturers Association (AAMA) and American Association of Quality Control (AAQC)

Rule- 40 defect points are accepted in 100 square yards of fabric. It is called 4 point system.

The length of defect of both side of warp & weft in fabric distribute of point:

0--- 3” defect --- 1 point3”--- 6” defect --- 2 point6”---- 9” defect --- 3 point9” and above --- 4 point

Hole & opening are always 4 point Maximum 4 defective points are acceptable in a yard

Gradation of Grey Fabric

Grade Dyeing Printing

A 0-- 12.75 point /100 0—21.37 point /100

Sq yard sq. yard

B 12.76—21.00 point / 100 21.38—26.62 point /

Sq. yard

C Above 21 point / 100 above 26.62 point /

Sq. yard 100 sq. yards


Processing UnitLIST OF PROCESSING MACHINERIES:

(A) BACK PROCESS MACHINES:-1) BATCH PREPARATION MACHINE: 3.20 MTRS WIDTH = 1 NO

2) SINGEING & DESIZING MACHINE KUSTERS, SWISS: 3.20 MTRS WIDTH = 1 NO PAREX, UK: 3.20 MTRS WIDTH = 1 NO

3) BLEACHING RANGE:- KUSTERS, SWISS: 3.20 MTRS WIDTH = 1 NO OMEZ, GERMANY: 3.20 MTRS WIDTH = 1 NO

4) WASHING MACHINE:- OMEZ, GERMANY: 3.20 MTRS WIDTH = 1 NO

(B) STENTER MACHINES (5 NOS):- i) MARSHALL & WILLIAMS, USA: 3.00 MTRS WIDTH = 1 NO. ii) BRUCKNER, GERMANY: 3.20MTRS WIDTH = 1 NO. iii) FAMATEX, GERMANY (3 NOS) : 3.20MTRS WIDTH = 1 NO. : 3.60 MTRS WIDTH = 1 NO. : 2.40 MTRS WIDTH = 1 NO.

(C) DYEING MACHINES:- i) MONFORTS THERMOSAL RANGE : 3.20 MTRS WIDTH = 1 NO ii) KUSTERS COLD PAD BATCH: 3.20 MTRS WIDTH = 1 NO

iii) KLEINWFFERS PAD STEAM DYEING: 2.00 MTRS WIDTH = 1 NO iv) MEZZERA JIGGERS: 3.20 MTRS WIDTH = 2 NOS. v) SMITH JIGGERS: 3.20 MTRS WIDTH = 4 NOS.

vi) JET DYEING MACHINE: = 8 TUBES

(D) PRINTING MACHINE (4 NOS):- i) ROTARY PRINTING MACHINE:-

ZIMMER, AUSTRIA – 12 Colors: 3.20 MTRS WIDTH = 2 NOS. REGGIANI, ITALY – 16 Colors: 3.20MTRS WIDTH = 1 NO

ii) FLAT BED PRINTING:- REGGIANI, ITALY – 12 Colours : 3.20MTRS WIDTH = 1 NO

(E) CURING MACHINES:- i) STEAMAGER, STORK, Netherlands: 3.20 MTRS WIDTH = 1 NO

ii) STEAMAGER, ARIOLI, Germany: 3.20 MTRS WIDTH = 1 NO


iii) POLYMERIZER, ARIOLI, Germany: 3.20 MTRS WIDTH = 1 NO.

(F) SANFORISING MACHINE (MORRISON): 3.20 MTRS WIDTH = 1 NO.

Mending Unit:


Receiving fabric from our weaving department & other grey fabric supplier Inventory grey fabric according to invoice / packing list Unfolding grey fabric Properly checking the grey fabric on mending table according to 4 point system Mending the grey fabric if there is any fault Folding the grey fabric in folding machine Sending the checked grey fabric to processing section

Bleaching, Dyeing and finishing Unit:

Back Process:

Singeing & Desizing


Receiving grey fabric from Mending & Inspection Section Folding the fabric in beam Setting the fabric beam in Singeing & Desizing machine Singeing & Desizing the fabric according to requirement Sending the fabric to scouring machine

Functions of Singeing:

Singeing - Remove the hairiness of grey fabric

Functions of Desizing: Desizing- Destroy the sizing chemicals of fabric


Chemicals used for Desizing

Poly Cotton Cotton

Baylase AT02 Baylase AT02Carbon salt Lusynton exPCLF PCLFAcitic Acid Acitic Acid

Lusynton red

Scouring


Receiving desized grey fabric beam Setting the beam in Scouring machine Scouring the fabric as per requirement Sending the fabric to Bleaching

Functions of Scouring

Remove the dust of grey fabric Increase the absorb power of grey fabric.

Chemicals used for Scouring

Poly Cotton Cotton

Karalon Caustic Soda Caustic Soda Karalon Sirrix AK

Bleaching


Receiving the fabric beam from Scouring Unit Setting the fabric beam in Bleaching machine Bleaching the fabric in the Bleaching machine Sending the fabric roll for dying/ printing

Functions of Bleaching


Remove the grey color of fabric Improve the whiteness of fabric Improve the absorbency of fabric

Chemicals used for Bleaching

Poly Cotton Cotton

Hydrogen per oxide Hydrogen per oxideCaustic Soda Caustic SodaStabilizer S.O.F Stabilizer S.O.FKaralon Karalon

Sirrix AK

Chemical used for Full White Fabric: B.B.U

Dyeing Unit

Types of Dyeing Process: Two Types

Disperse Dyeing (for PC – Jet Dyeing) Re-active Dyeing (for Cotton – Jigger Dyeing)

Chemicals used for Disperse Dyeing

Acitic Acid Lycol-O-Powder

Chemicals used for Re-active Dyeing

Soda Glover Salt

Functions of Dyeing

Set up base for fabric Width setting Heat setting Chemical setting as per requirement


Mercerizing

Function

Improve the glace of fabric Improve absorbency

Dyeing

Deep color mixing Light/Pastel color mixing

- Jet & Jigger Machine - Stander Machine- Pad steam “- Thermo sol “

Production Capacity / Hour

Desizing 5,000 meter / hour

Scouring 4,000 meter / hour

Bleaching 3,500 - 4,000 meter / hour

Calendaring:

Function

Iron the fabric for folding

Folding Section

Function:

Folding the fabric by folding machine and delivery the fabric to Garments Unit


Printing Unit

Designing


Receiving the design from Export Department Checking and coloring the design Modifying the color combination if not matching with the specification Setting the direction of design Making the design in film format Sending the film to Engraving Unit

Engraving


Receiving the screen roll Coating the screen roll by using a chemical (Name of the chemical: Photo Emulsion) Heating the screen roll by Climitizer machine Setting the screen roll in the Exposing machine Exposing the film to make design in full screen by taking various steps Washing the screen roll for printing process Heating the screen roll by Polimizer machine Setting the screen roll in Touching stand to remove the unnecessary spot/color by using a

chemical (Name of the chemical: Retouching Lacquer) Setting the screen roll in Indring ring to fix the starting point by using Indring Glue. Sending the screen roll to Printing machine for printing

Printing Process



Setting the screen roll in printing machine according to design & color Setting the fabric roll in printing machine Making the color combination in color kitchen Using the same color combination in screen roll for printing Printing the fabric in the printing machine Sending the printed fabric for curing

Curing Unit

Function

Fix up the color and design by heating

Stenter (Finishing):

Function

Final finishing touch for fabric

Calendaring:

Function

Iron the fabric by heating for folding

Folding Section

Function

Folding the fabric by folding machine and delivery the fabric to Garments Unit

Types of Printing Process:

Three types of Printing Process are followed in Alltex industries Limited

Disperse Printing (for Polyester ) Re-active Printing (for Polyester) Pigment Printing (for PC + Cotton)

Chemicals used for Disperse Printing


Sodium LG Net Soda Ash Sodium bi-Carbonate

Chemicals used for Re-active Printing

Sodium LG Net Citric Acid Printox Gum

Chemicals used for Pigment Printing

Binder Thickness Lycquer Ammon

Production Capacity / hour

Printing (for PC) 3,000 ~ 3,500 meters / hour (depends on design & quality)

(For Cotton) 2,000 ~ 2,500 meter / hour (depends on design & quality)

Curing (for PC) 3,500 ~ 4,000 meter / hour

(For Cotton) 3,000 ~ 3,500 meter / hour

Folding (for PC) 2,000 ~ 2,500 meter / hour

(For Cotton) 1,500 meter / hour

Finishing 1,200 meter / hour

Some General Information

o Scouring is not applicable for printingo No. of Printing Machine: 2 (Zimmer, Austria)o No. of Curing Machine: 2o No. of Calendaring Machine: 2o No. of Folding Machine: 6o Color Capacity: 12


o Design Repeat: 642 mm, 914 mm

Laboratory UnitTypes of Test:

Lab Department is usually following Two Types of Test:

1. Sample Test2. Bulk Production Sample Test

Functions of Lab Department:

Laboratory Department has Two Functions:

1. Lab Dip2. Quality Control

List of Tests followed by Lab Department:

Dimensional Stability Tensile Strength Tear Strength Seam Slippage Seam Strength Rubbing/Crocking Abrasion Pilling C/F to Wash C/F to Water C/F to Perspiration C/F to Light Formaldehyde SA Rating Appearance PH of Fabric Migration on PVC Foll Wash ability C/F to dry clean Count Construction Fiber Composition Iron ability Fabric Weight


Multi Wash Durability Density

Uses of Lab Testing Machines:

1. Verivide Cabinet (Equiptex, England) : It is used for color matching testing.

2. Viscometer (Rheology, UK) : It is used for measuring Tension from any liquid.

3. Data Color Spectrophotometer (USA) : It is used for matching the color shade of production sample with the master sample and also determining whether it is passed or failed. (Up to .75 ----- Pass, .76 to 1 ----- Warning, Above 1 ----- Fail)

4. UV/VIS Spectrophotometer (USA) : It is used for Formaldehyde testing.

5. Microsol (England) : It is used for color fastness testing.

6. Abrasion & Pilling Tester (SDL, UK) : It is used for poplin test of the fabric.

7. Crease Recovery Tester (J.H. Heal, UK) :It is used to determine the recovery angle of crease.

8. Wascator (J.H. Heal, UK) : It is used to measure the shrinkage, recovery and fade of the fabric by using washing detergent. (Name of Detergents: i) Sodium Per-borate ii) Non Phosphate Reference Detergent). Washing times: 1 ~ 5/10 times as per buyer requirement. Degree of Heating: 50 ▪. Fabric required for shrinkage/recovery test: 35 sq. cm.

9. Household Washer(Prima, Italy) : It is used for testing by washing the fabric.


10. Rubbing/Crock Meter (SDL, UK) :It is used for measuring the color staining from color fabric by setting on the 100% bleach cotton fabric.

11. Tumble Dryer (Zannusi, Italy) : It is used for tumble drying. Three ways of Tumble Drying: i) High ii) Medium iii) Low

12. Gyro Wash (J.H. Heal, UK) : This is one type of washing with multi-fiber by using various types of detergents. Washing Duration: 30 minutes, Degree of Heating: 60▪

Fabric required for Gyro Wash: 40/100 mm or 4/10 cm.

13. Vertical (2 Bowl) Padder (Rapid, Hong Kong) : It is used for continuous dyeing, stantering and pigment dyeing by using dyeing chemicals.

14. Laboratory Saturated HT Steamer (Rapid, Hong Kong) : It is used for curing the dyed fabric.

15. Fong’s (Fong’s, Hong Kong) : This machine is used for disperse dyeing.


Stitching unit

Folding & Folding Inspection:


Receiving the finished fabric from processing unit Checking the finished fabric properly on inspection table Mending the fabric if there is any fault Taking the color shade approval for dyed fabric from Quality Assurance Department Sending checked fabric for Cutting section

List of Dyeing and Printing Faults:

Dyeing Faults:

Color burn Line mark Weaving fault Neps Spot Miss pick Double pick Damage Hole Ring Spot Foreign yarn

Printing Faults:

Design out Color burn


Spot Crease mark Color short Color bleeding White spot

22

Gradation System of Finished Fabric Quality:

0”--- 3” defect ---- 01 point

4”--- 6” defect ---- 02 point

7”---- 9” defect ---- 03 point

9” and above ---- 04 point

Point Grade (for Dyeing)

12 “A”

13 ~ 30 “B”

31 and above “C”

Point Grade (for Printing)

16 “A”

17 ~ 32 “B”

33 and above “C”

Basic formula:

Total Point x 100x 36” ` = Grade Point Total Length x 1 x Fabrics Width

Cutting Unit



Receiving the checked fabric from Folding & Folding Inspection Department Lying the fabric on Cutting table Marking the fabric according to product size and dimension Cutting the fabric by following the cutting mark Sending the cut fabric to Stitching Unit for stitching

Total Cutting Quantity / day ------------------- 1, 10,000 meter / day (Average)

Cutting Quantity / day (Item wise)

Quilt Cover --------------------- 30,000 meter / day Flat Sheet ----------------------- 20,000 ~ 25,000 meter / day Fitted Sheet --------------------- 25,000 ~ 26,000 meter / day Valance Sheet ------------------ 20,000 ~ 21,000 meter / day Pillow Case --------------------- 30,000 meter / day Curtain -------------------------- 25,000 ~ 26,000 meter / day

General Information:

No. of Cutting Unit: 4 (including Megatex) No. of Cutting Table: 21 No. of Cutting Machine: 8

Stitching Unit:


Receiving the cut fabric from Cutting Unit Collecting the necessary accessories (Button, Thread, Label, Elastic) from the Store Department. Stitching the fabric by following the master/sample product Sending the finished product to Product Quality Unit


Types of Stitching Machine

Plain Stitch Flat Lock Over lock Twin Needle Blind Stitch Button Hole & Attachment

Stitching Quantity / hour (Item wise):

Product Name Product Size Quantity / hour SB 60 pcs DB 55 pcs Flat Sheet KB 40 pcs SKB 35 pcs Required Sewing Machine: i)Lock Stitch Required Accessories:

i) Care Label ii) ii) Thread

Product Name Product Size Quantity / hour

Fitted Sheet SB 55 pcs DB 45 pcs KB 40 pcs Required Sewing Machine: i) For Box – Over Lock ii) ii) For others - Lock StitchRequired Accessories:

i) Care Label ii) Thread iii) Elastic

Product Name Product Size Quantity / hour Platform Valance SB 12 pcs Sheet DB 12 pcs


KB 12 pcs Required Sewing Machine:

i) For Frill – Over Lock ii) ii) For others - Lock Stitch

Required Accessories: i) Care Labelii) ii) Thread

Product Name Product Size Quantity / hourFitted Valance SB 12 pcs Sheet DB 12 pcs KB 12 pcs Required Sewing Machine:

i) Box & Frill – Over Lock ii) Others – Lock Stitch

Required Accessories: i) Care Label

ii) Thread

Product Name Product Size Quantity / hour Quilt Cover SB 45 pcs DB 40 pcs KB 35 pcs SKB 30 pcs Required Sewing Machine:

i) Plain ii) Over Lock iii) Button Hole & Attach

Required Accessories:i) Care Labelii) Thread iii) Button iv) Zipper

Product Name Product Size Quantity / hour Without Liner with Liner with Eyelet


Curtain 46x72 24 pcs 14 pcs 6 pcs 66x72 18 pcs 12 pcs 4 pcs 66x90 15 pcs 10 pcs 4 pcs Required Sewing Machine: i) Plain ii) Over Lock iii) Twin Needle iv) Blind Machine v) Eyelet Hole vi) Eyelet Joint

Required Accessories: i) Care Label ii) Thread iii) Important or Hanging Instruction iv) Heming Tape v) Eyelet vi) Interlining

Product Name Product Size Quantity / hourPillow Case H/W 80 pcs Oxford 56 ~ 60 pcs Frill 50 pcs Neck 30 pcs Bolster 70 pcs Pillow Case with Three Side Liner 25 pcs Pillow Case with Embroidery 25 pcs (Two part ribbon joining) Required Sewing Machine: i) Plain Stitch ii) Over LockRequired Accessories: i) Care Label ii) Thread

Stitching Faults:1) Deviated/Skipped/Broken Stitch2) Open Seam3) Uneven Hem4) Uneven Margin5) Uneven Top Stitch/ Stop-in6) Uneven Side Seam7) Uncut Thread8) Puckering Seam9) Raw Edges10) Tension Loose11) Loose Thread12) Tack Missing13) Elastic Visible14) Hem Roping15) Unwanted Pleat16) Size Mistake17) Product with Marking Tape18) Wrong Direction19) Pen Mark


20) Insecure Tacking21) Misprint Label22) Embroidery Label23) Twisted (Elastic Puckering)24) Selvedge Visible25) Lashing Mark26) Improper Button Alignment27) Incomplete Button Stitch28) Dirty Spot29) Black Spot

List of Garments Accessories: 1. Button:

Plastic Button

Metal Button

Wooden Button

Two Hole Button

Glass Button

Four Hole Button

2. Thread:

Sewing thread

3. Label Oven Label

Non-Oven Label

4. Eyelet5. Elastic6. Interlining7. Hook8. Zipper

Plastic Zipper Metal Zipper

General Information:

No. of Stitching Unit: 4 (including Megatex) No. of Stitching Machine: 450 Allowance in Plain & Over Lock Stitch: 3 cm Stitch / inch: i) for Plain Stitch --- 9 ~ 10 ii) for Over Lock --- 8 ~ 10


60 meter Thread required for a 2 cm Button Hole Thread Consumption: 1 cm = 2.5 cm Thread (for Plain Lock Stitch)

1 cm = 17 cm Thread (for Over Lock Stitch)

Product Quality Unit


Receiving the finished product from the Stitching Unit Checking properly the finished product on the Inspection Table

- Checking the fabric quality- Measuring the product size & dimension- Checking accuracy of the accessories of specific product- finding the product fault for mending

Mending the product if there is any fault Sending the checked product to the Pressing & Packing Unit

Pressing & Packing Unit


Receiving the checked product from Product Quality Unit Pressing the product and folding with stiffener board according to Buyer’s requirement Packing the product & setting the packing accessories properly Setting the packed product in carton box for export

List of Packaging Accessories:

1. Poly bag: PP (Poly propylene) PE (Poly Ethylene) PVC( Poly Vinyl Chloride)

2. Inlay Card/U-Card

3. Stiffener

U. Fold

B. Fold

Flat Fold

4. Size Sticker5. Price Sticker6. Barcode


7. Catalogue Sticker8. Important Sticker9. Strapping10. Gum Tape11. Safety Sticker12. Master Poly13. Carton Pack

List of Packaging Mistakes:1. Supplying of wrong packaging materials2. Barcode missing3. Inlay card missing4. Size sticker missing5. Wrong carton paper6. Product size mistake7. Poly bag size mistake8. Price sticker missing9. Safety sticker missing

Carton Sizes (as per Buyer):

Name of the Buyer Product Name Carton Sizes

IKEA Quilt Cover+ 76x53x11.5 cm Pillow Case+ Curtain 53x38x18 cm 57x38x23 cm 57x38x18 cm

Ekkelboom Quilt Cover 9x29x42 cm

Fitted Sheet 37x23x37 cm 37x23x24 cm 37x23x29 cm Pillow Case 43x29x27 cm

Leon Kremer Quilt Cover 40x30x40 cm

K - Mart Sheet Set (SB/QB) 35x26x46 cm (Flat+Fitted+Pillow Case) Sheet Set (DB/KB) 35x26x50 cm


REDCATS(La-Redoute) Quilt Cover (KB) 55x36x27 cm Brand Fitted Sheet (SB) 35x29x40 cm Fitted Sheet (DB) 35x29x35 cm Pillow Case (H/W) 50x29x24 cm (Flat Sheet + Fitted Sheet + 59x29x19 cm Pillow Case + Bolster)

REDCATS(Empire Brand) Quilt Cover + 39x29x39 cm Fitted Sheet + Flat Sheet + Valance Sheet Pillow Case REDCATS (Ellos Brand) Fitted Sheet + 39x29x34 cm Flat Sheet + Valance Sheet Pillow Case


REDCATS Valance Sheet + 60x30x20 cm

(Daxon Brand) Pillow Case

TESCO Quilt Cover (DB) 55x36x23 cm Quilt Cover (KB) 55x36x27 cm Fitted Sheet + Pillow Case 35x29x40 cm 35x29x35 cm

Turner Bianca Quilt Cover (SB/DB/KB) 39x29x39 cm Flat Sheet + PVS + FVS + 37x30x37 cm (SB/DB/KB/SKB) 37x30x12 cm 39x29x36 cm 39x29x33 cm Pillow Case (H/W) 37x24x37 cm 31x23x18 cm

LECLERC Fitted Sheet (SB) 35x25x24 cm (DB) 37x35x24 cm


(KB) 39x25x24 cm Flat Sheet (SB) 43x29x23 cm (DB) 45x30x28 cm Pillow Case 43x18.5x18 cm Bolster 44x34x13 cm Quilt Cover 44x32x21/30/33 cm

Turner Bianca Fitted Sheet (DB) 39x33x37 cm (Argose) (KB) 39x30x32 cm Quilt Cover (DB) 39x33x26 cm (KB) 39x30x32 cm Pillow Case (Oxford) 32x26x32 cm Curtain (Eyelet) 39x29x36 cm

Turner Bianca Fitted Sheet + Flat Sheet+ 37x29x31 cm (Home Base) BFVS + Quilt Cover + Pillow Case

Vanguard Fitted Sheet + Flat Sheet+ 38x28x38 cm BFVS + Quilt Cover + PVS 32x28x38 cm

Folding Sizes (as per Buyer Requirement): Name of the Buyer Product Name Carton Sizes

IKEA Quilt Cover+ 24.5x35.5 cm Pillow Case+ Curtain + Without Barcode Flat + Fitted Sheet With Barcode (SB/DB/KB) Ekkelboom Quilt Cover (SB) 26x36x2 cm 25x35x2 cm

(DB) 26x36x3 cm 25x35x3 cm (KB) 26x36x4 cm 25x35x4 cm

Fitted Sheet (SB) 20.5x35x2.5 cm

Leon Kremer Quilt Cover 26x36 cm

K - Mart Sheet Set 24x33x5 cm


(Flat+Fitted+Pillow Case) 24x33x6 cm Sheet Set (SB/DB/KB/SKB) 24x33x6.5/7 cm

Calitex Quilt Cover + 28x38 cm Pillow Case (SB/DB/KB)

Turner Bianca Quilt Cover (SB/DB/KB) 15x37x3/4/5 cm

(PC Percale) Fitted Sheet (SB/DB/KB) 15x37x2/2.5/3 cm

Pillow Case 15x24 cm

TESCO Quilt Cover (SB/DB/KB) 26x31.5x2.5/3.5/4.5 cm Flat Sheet (SB/DB/KB) 12.5x32x3/4/5 cm Fitted Sheet (SB/DB/KB) 12.5x32x2.5/3.5/4.5 cm Pillow Case 11x23 cm Turner Bianca Quilt Cover (SB/DB/KB) 28x28x4/6/6.5 cm (Next) Fitted Sheet (SB/DB/KB/SKB) 11x32x3/4/5/6 cm Box Valance Sheet 11x32x4/5.5/6 cm (SB/DB/KB)


LECLERC Quilt Cover (SB) 20x26 cm (DB) 20x26 cm (KB) 20x26 cm Flat Sheet (SB) 20x26 cm (DB) 20x26 cm (KB) 20x26 cm

Turner Bianca Fitted Sheet (SB/DB/KB/SKB) 16.5x36x2/2.5/3/3.5 cm

(Argose/Home Base) Quilt Cover (SB/DB/KB) 16.5x36x3/5/5.5 cm

Flat Sheet (SB/DB/KB/SKB) 16.5x36x3/3.5/4/4.5 cm Box Balance Sheet (SB/DB/KB) 16.5x36x4/5.5/5.5 cm PVS (SB/DB/KB) 16.5x36x3/4/5 cm Pillow Case 16.5x22.5x2 cm

Turner Bianca Fitted Sheet + Quilt Cover 27x37x2/2.5/3 cm


(DunnelM) (SB/DB/KB)

Vanguard Fitted Sheet (SB/DB/KB) 26x36 cm

Flat Sheet (SB/DB/KB)

Quilt Cover (SB/DB)

Box Balance Sheet (SB/DB)

PVS (SB/DB/KB)

Quilt Cover (KB/SKB) 26x36x3 cm (Book Fold)

Box Balance Sheet (KB/SKB) 26x36x2.5 cm (U. Fold)

Pillow Case 18x26 cm

Hassan & Associates Fitted Sheet (DB/KB) 14x22x5 cm

Flat Sheet (DB/KB)

Box Balance Sheet (DB/KB)

Chapter-Eight


Quality Assurance System

Sampling Department:


Receiving sample requisition from Export Department Collecting the required fabric from Folding Unit to make various sample Matching the color shade for dyed fabric with original swatch or pantone no. # and for

printed design with master design. Checking the fabric quality and giving approval comments Remaking the sample as per buyer comment for second time submission if there is any

comment from the respective buyer

Approval Procedures:

White tag : A white tag is a proto type product that has been provided by the supplier for sales consideration.

Red tag : Red tag is the next approval stage from white tag (which can become red if sold as seen). This is also the first approval stage by the buyer.


Amber tag : This is an agreement of first bulk delivery acceptance must be turned to a green tag on second delivery.

Green tag : Approved of bulk production samples and overrides the red tags. This must be matched with all future bulks.

Gold seal tag/sample : Approved fully complete packed product (It does not override the green tag, but it is kept internally as a representation of the accepted shipment standard.

Embroidery:


Receiving the buyer design from Export Department Sending the design to selected factory for sample Checking the design and match the color of sample with original design Collecting the embroidery rate from factory Sending the sample & rate to Export Department for approval If approved then proceed to bulk production by the respective factory

Bulk Fabric Approval:


Collecting dyed fabric swatch from Folding Unit Matching the color shade with original swatch or pantone number

- Visual system- normal check- CMC (Color Matching Comment)- lighting check- .90 - .99 acceptable

Accessories Approval:


Receiving the sample of accessories from Packaging Department Checking the accessories as per requirement

- Checking the quality- Measuring the size and dimension

Checking the design


If there is any fault then advising to Packaging Department to amend the accessories to fulfill the buyer requirements.

Final Inspection:


Receiving packing list and vendor declaration from Export Department Comparing the vendor declaration, product list and order sheet Colleting the necessary lab report Checking the carton weight Checking the label size & its accuracy Scanning the barcode and comparing with article number Checking the poly pack quality Measuring the product size and dimension Comparing the product shade with approved shade Checking the logo Checking the instruction in all labels Checking the product for defect and workman ship Noting all defects in the inspection report as per requirements Filing the inspection report and sending that report to the Export Department for approval

CERTIFICATE AWARDED ISO 9001 – 2000 Oeko - Tex Standard - 100. BRC Global Standard, UK IKEA Approved Supplier Organic Exchange & GOTS ** Awarded Best vendor of the year by Target Corp (AMC)


Chapter-Nine

Store www.AssignmentPoint.com

& Inventory control

AndUtilities

Inventory in a wider sense is defined as any idle resource of an enterprise in order to meet expects of demand or distribution. It is commonly used to keep hold inventory of various kinds to as cushion between supply & demand.

Frequency of inventory control: Monthly inventory control Annual inventory control

Scope of inventory control: Raw materials Dyes store Others chemicals store Finishing fabric spare parts General store


Capital equipment Accessories Stationary Maintenance parts.

Inventory system for raw materials: Raw materials partially received from production planning & directly from head office. Material Receiving & Inspection Report (MRIR) is prepared. Received quantity is

mentioned & noted down. Submitted to QC department. Some are OK & few rejected. Entry of data of goods in DATATEX. Goods are arranged according to OK or rejected group. Department gives store requisition to warehouse. As per requisition materials supplied & this record is noted down.

Stages of grey fabric inventory control: After production Grey inspection Warehouse Batch preparation Dye house.

Stages of finished fabric inventory control Finishing section After final inspection Warehouse.


Remark s

The inventory system of AIL covers the whole inventories. The space is noticed to be insufficient considerably. An expansion of space is thus desired for sound inventory.

POWER AND SERVICES

GENERATORS (2 NOS):-

CATTER PILLER GAS ENGINE GENERATOR (1275 KVA) = 2 NOSWAUKESHA GAS GENERATOR (1375 KVA) = 1 NO

BOILERS:-

STEAM BOILER: ROLLS ROYES COCHRAIN (6000 KG+ 10000 KG) = 2 NOSOIL BOILER: INPLAN, ITALY (4 MILLION KILLO CAL) = 1 NOOIL BOILER: BEVERLY, UK (2.5 MILLION KILLO CAL) = 1 NOOIL BOILER: THERMOTECHNIC, GERMANY (1.2 MILLION KILO CAL) = 1 NO


Chapter-Ten

Conclusion


I have completed our industrial attachment successfully by the grace of Allah. Industrial attachment sends us to the expected destiny of practical life. The completion of the two months Industrial attachment at ALLTEX INDUSTRIES LIMITED we have got the impression that factory is one of the most important export oriented Home-textile composite complex in Bangladesh.

During our training period, talking with the clients of this mill we knew that the mill is fulfilling the country’s second best export oriented home-textile products as well as very good colored fabric due to its modern machinery & good management system.

Mill is settled with utility to give all convenient supports to the productions for twenty-four hours. It had self-power generator system to satisfy total power consumptions of the mill. We are enough fortunate that we have got an opportunity of having a training in this mill. During the training period we are received co-operation and association from the authority full & found all man, machines & materials on appreciable working condition. All stuffs & officers were very sincere & devoted their duties to achieve their goal. We are lucky to get the opportunity of having training in this mill.

The factory runs by a number of efficient Textile Engineers, Skilled technical & Non-technical persons. All the Textile Engineers, technical & Non-technical persons are very sincere, co-operative and helpful.

We wish good luck of them and also for this factory. It was really a productive practical learning besides our four year academics, so we wish we will be able to implement our learning and methodological knowledge successfully in the textile industry and the betterment of the economy of my Country.


· Web viewAs a new beam (or article) is set to a loom either by drawing cum gating or tying, it...

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Transcript of · Web viewAs a new beam (or article) is set to a loom either by drawing cum gating or tying, it...